Method and apparatus for making foambacked materials in broad widths and product thereof



R. D. THOMPSON 2,947,346 OR MAKING FOAFVFBACKED MATERIALS IN BROAD Aug. 2, 1960 METHOD AND APPARATUS F WIDTHS AND PRODUCT THEREOF Original Filed Jan. 27, 1954 3 Sheets-Sheet 1 INVENTOR. ROBERT D. THOMPSON 22 1 4? km ATTORNEYS Aug. 2, 1960 R. D. THOMPSON METHOD AND APPARATUS FOR MAKING FOAM-BAG WIDTHS AND PRODUCT THE Original Filed Jan. 27, 1954 INVENTOR.

N O P M m x 0W /J R I E 8& O Y B ATTORNEYS Aug. 2, 1960 R. D. THOMPSON 2,947,346

METHOD AND APPARATUS FOR MAKING FOAM-BACKED MATERIALS IN BROAD WIDTHS AND PRODUCT THEREOF Original Filed Jan. 27, 1954 3 Sheets-Sheet 5 d e FIG. II

IN V EN TOR. ROBERT D. THOMPSON BYwzljyli/mm ATTORNEYS METHOD AND APPARATUS FOR MAKING FOAM- BACKED MATERIALS IN BROAD WIDTHS AND PRODUCT THEREOF Robert D. Thompson, 1115 Jefferson Ave, Akron, Ohio Continuation of application SenNo. 406,560, Jan. 27, 1954. This application Oct. 25, 1956, Ser. No. 620,785

14 Claims. (Cl. 154-423) This application is a continuation of my copending application Serial No. 406,560, filed January 27, 1954, now abandoned.

. 2 Figs. 5, 6 and 7 are sections on the lines 5--5, 6--6, and 77, respectively, of Fig. 4.

Fig. 8 is a view looking at the underside of a section of spliced carpeting showing the various layers of ma- The present invention has been perfected primarily for i the manufacture of carpeting which is provided with an adherent underlay or cushion of foamed latex rubber sponge. The particular type of carpet material to which this invention is especially adapted is that type of sponge rubber backed carpeting in which the rubber latex foam is applied directly to the carpeting and then gelled and cured in place thereon. By this method the rubber foam penetrates into the base of the carpet, where it is vulcanized. While other processes and. machines may be found to make the sponge rubber backed carpet, it is preferred to use the process and apparatus of Alderfer 'Patent No. 2,628,654, dated February 17, 1953.

The machine of the Alderfer patent, as well as other snachines in use in the manufacture of sponge rubber sheeting, have definite limitations as to the widths of material which may be coated and, in answer to demands "for wider materials, it has been found necessary to splice .widths by hand.

The invention of this application is for the purpose of developinga new and improved procedure for splicing widths of sponge rubber backed carpeting or other products quickly, easily, and with the minimum of waste and labor. In addition the splicing operation will be done so accurately that there is little or no visible evidence from the upper surface of the carpet that splicing has taken place, and the splice will be strong and will hold indefinitely.

The invention relates both to the method employed for the process and also to a machine by which the method inay be carried out with less labor and supervision. As the spliced product is new, that is also a part of the invention. 1

While the invention is particularly directed to the splicing of carpeting, it is not confined to that product but may i be used for other materials.

In the drawings there are shown sufficient of the steps of the process to enable the invention to be understood and there is also illustrated a machine which has been designed to carry out the splicing operations for the edges of two strips of carpet. In the drawings, the best known and preferredform of the machine is shown, it being understood that changes, modifications and improvements may be made without sacrificing the benefits of the invention.

In the drawings, Fig. =1 is a side elevation of an apparatus for performing the splicing operation.

Fig. 2 is a section on the line 2-2 of Fig. 1.

Fig. 3 is a top plan View of that portion of the machine where the splicing is done, the view being taken on the line 3-3 of Figs. 1 and 4.

. Fig. 4 is an enlarged side elevations of the parts of the machine shown in Fig. 3.

terial constituting the complete assembly.

Fig. 9 is a section through the spliced carpeting on the line 99 of Fig. 8.

Fig. 10 is a section through the selvage of a carpet material showing the first step in the process.

Fig. 1 1 is a similar section showing the second step in the process.

In the application of sponge rubber to carpeting, the older method consisted in making a layer of sponge rubber and adhesively attaching the vulcanized layer to the back of the carpet. As improved method which may be carried on in the machine of the Aldefer patent referred to above is to flow a layer ofunvulcanized and ungelled latex foam against the back of the carpet which, because the foam is largely water, will penetrate into the backing of the carpet. The latex foam contains gelling and vulcanizing agent and after the foam is applied in an even layer to the back of the carpet, the carpet is first led through a heated chamber where the foam is gelled and thence to a second chamber where the carpet is exposed to heated air which is caused to circulate around and through the composite material, vulcanizing the foam and removing any objectionable odors.

In applying a layer of foam to a width of carpeting, the foam will be extended close to the selvage edges so that when the selvage is trimmed the thickness of the sponge will be uniform throughout the carpet.

In the rug and carpet industry, carpeting has been spliced by the use of a tape backing applied on the under- 'side of two adjacent breadths of carpet along the buttseam.

It is impossible, however, to apply this method to buttsplicing of rubber sponge backed carpeting because the underlying layer of foam lacks tensile strength and stability, and will tear easily.

The process described herein consists in so modifying the, old processes of applying sponge rubber to carpet and it is possible to obtain as strong a butt-splice or will makeafirmbond.

seam as when there is no rubber sponge backing on the carpet.

Briefly stated, the process consists in laying on or loosely attaching to the edge of the carpet to be spliced and along the underside of the selvage, -a removable shield or foam latex impermeable barrier which will be interposed between the latex foam and the underside of the carpet to provide the underside of the carpeting with a band or area extending laterally inwardly from the selvage edge and which will not become firmly attached to the rubber sponge when cured and which will be of sufficient width to afford a good anchorage for the splicing tape. Then, the rubber sponge is cured and bonded to the underside of the carpet.

The next step is to longitudinally trim the selvage from two breadths of carpet to be spliced and to bring the edges of the carpet into abutment. The edges of the foamed layers are then turned up to expose the unrubberized edge areas of the fabric base and the splicing the finished seam If desired, a second tape or finishing tapemay be applied over the exterior of the seam.

The material which is used as the foam latex impermea e ar between he tea nzan t bas of th p arp may be a gauze or paperan'd thrown away when the isnliceis ma e, .Q ;-n ay:;b anoating o .paint: or sh whi h wi p v n t v.r bberteam from pen tra in into the base of the carpet.

. nfi drawi th numera .A andA' ar appl to two breadths of carpeting which itgis ,desiredto butt- ;sn iq a n he a iac nted e th e r g urf of each adth be n a pil w a ri w n in th usual rnanne t th lQQ lyw i n-sba .ai r-a ,Ea hbreadth of carpet has the usual selvage c or c.

; .io, t in ro ucing h carpet breadth into the aph s-h appl thexuh e arn, th irnp rmeabi rtedtbabW fis appl e to the undersid f th atn t alon th se a ed and th n her of ex e ds l te ally a xl y sufiicient dis n e t term .a pocke o t e es ed e ten b ne th th e g f th carpe .Suc a l ieldc lat x te m impe m le ar i i shcwna A v noted o e, this may b p per, ,gauze, foil, or even acoating of shellac or paint. If :paper or gauze or .foil-is used, this may be removed just before thesp lieing operation; if paint or shellac is used, it should be of such a character that the splicing tape wil eadhe e wit-wi suifi ien tena i y t f rm a firm bp nd.

he parapetis ow .coat don its underside with a layer of latex-foam of the desireddepth, which will penetrate the ;baseof the parpet laterally of the barrier, but which eapnot penetrat and adhere-to the-barrier. Such a layer qf foam-is glicated at e or e. When it .is gelled and cured, it will form ;a ,soft yielding layer permanently attached by a vulcanized bond to the underside of the .earpet. Beeause'the sponge layer is composed of a muludeof sn1a1l cells located in the rubber and communicating with each other and with the interstices of the .eagpet, {the-carpet will ventilate throughout. 1

:QQXM EP in the process ,is to longitudinally trim the sel a e en the edges of the arpct'to a line Wi hin the pile fabric, such a line being indicated by the line ift- -f-jinifig. ;151. The sponge rubbe can now be turned b k in;the area of the barrier d and the barrier may be ,removed and disposed of if paper, gauze or foil was ,usegi. 'ljhe edges of the carpeting are then abutted and the splicing strip h is laid in the pockets thus exposed and firmlyhondedto the underside of the selvage edges o the ca pe f-IIhe edges of the sponge rubber layer are vnow replaced ar d-sealed .to the splicing strip, if desired, and as aiinal step the finishing tape i may be now applied and adhered over the splice between the two carpet br adths The method as described is not only novel but the spliced product is likewise new and useful.

The apparatus comprises atable 10 on which the two strips A, and :A' of carpet having .the sponge rubber backing vulcanized thereon are laid with the selvage edges overlapping as shown in Fig. 2. The two strips of carpet are fed into the revolving knife 12 mounted on a .driven shaft 13 supported in brackets 14 depending from a framework 15. The knife 12 cuts of1 the two selvage edges, that from the upper carpet A being conducted upwardly onto abelt 16 which carries it away. The other selvage edge for the lower carpet A is led over the end .of the table 10, where it falls into a scrap container.

The two strips of carpet, which, after they leave the knife 12, are trimmed and butted together, are now transferred to any suitable conveyer on which they are to be spliced. A type of such conveyor is the large drum 20 .which is driven in the direction of the arrow in Fig. 1.

This drum is of suificient width to support the two strips oficarpetv The carpet strips or breadths are pressed against the 4 surface of thedrum 20 by two .rollers 22 .andr23carried in a frame 24 depending from an adjustable bracket 25 at the end of the supporting frame 15. These rollers serve to hold the two breadths of carpeting against the drum and in edge-to-edgerelation with the foamed rubher on the outside of thedrum.

As the carpet breadths aapproach'the top :ofithe;drum, h y meet the plowzshaped leading end .of'ra generally oblong frame indicated as a whole =:b.y -;the.m1meral30. The underside of the frame is curved so as ..to.,clear the carpet on the surface of the drum and has two parallel uprightwalls which are ijoinedat either end .to. triangular end plates '32 which are :suspended by adjustable 'holts 34, the upper ends of which are held in brackets 35 that are attached to apair ,of horizontal beams 36 forming a part of an overhead structure.

The ends of the plates 32 are tapered toward one another: and :toward :the surface of tthe. drum to :formitwo plow-shaped tends, indicated by .the numerals and 39 in Fig. 3, the points of the plows :noinciding with the :line .of separation :between the two zcarpet tbreadths and .spaced from zthe surface of *the drum, so :as :to .:cle.ar the 'edgeso'f the;carpet. As the two breadths of carpet approach #the .plowt, the two edges of the rubber :sponge e and .e are lifted and .turnedkback :as shown in Figs. 5 and '6. They will ride along thewalls v31 until the plow .39 is reached, whereupon they willreturn .to their original positions.

During the periodthat the rubber layers :are lifted, the undersides of the carpets :are exposed and during this time the splicing tape h is applied to? the edges of the carpet. I

The tape h is :supplied from :a supplyroll 42 'whichis supported :on side rails 43 of the upper :framework. One' sideof this tape is coated with a tacky adhesive-which -.will adhere the tape to the exposed underside of the carpet. .From the supply .roll 42 the tape is 'led under to 1t-he:tap e. The roller 50 is located at the lowerend -.of side frames 51 which .are supported from brackets i g 1 .1 11 the beams 36. ,The roller .50 receives the cement from a series of feed rollers 53 and ,54, the

latter being supplied fromrthe tank ,55 located in the upper ends of the frame '51. r The freshly cemented splicing :tape is in condition t receive-the flaps of the sponge rubber layer whichfollow down over the plow 39 and thence to a pressure roller 58 mounted in a fork 59 ,adjustably suspended from an extension 69 of the beams 36. Thisrolls the unattached edges of the sponge rubber in place against the tacky surface of the tape it.

If the finishing strip i is applied, this is stored in a roll 62 mounted in brackets 63 on the upper supporting structure, the strip being conducted o'veraguide roll 65 and beneath ,a pressure applicator roll 66 mounted in a fork 68 which is ,adjustably suspended from the beams 60 by threaded bolts 69. The surface of the finishing strip i is adhesively coated .on the side which is applied to the surfaces of the foam.

If desired, that portion of the drum adjacent the seam may be heated to facilitate the setting of the various adhesives.

It will be seen that there is provided a method and apparatus by which a firm connection may be made between two "lengths .of carpeting having applied thereto a sponge rubber-backing and particularly one in which the sponge rubber backing is connected "to the carpeting by a permanent vulcanized bond. 'While the process :and apparatus are shown as unitingonly two widths of carpeting, the number of widths may be increased if desired. While a large drum such as shown at 20 is preferred, a conveyer of the belt type may be substituted in which case the frame 31 will be shaped accordingly. Where the term conveyer is used in the claims, it will be understood that this is meant in the broad sense and will cover any type of supporting and conveying device. It

is also possible to move the whole frame 30 relative to the carpet.

What is claimed is:

1. An apparatus for the manufacture of multiple strips of carpet having layers of yulcanized sponge rubber attached to the undersides thereof, comprising means for conveying two strips of carpet in edge-to-edge relation, means for separating the adjacent edges of the sponge rubber layers from the undersides of the strips, means to apply a splicing element having an adhesive coated side with said coated side in contact with the exposed undersides of the strips while the sponge rubber layers are separated from the strips, andmeans to adhesively unite the edges of the sponge rubber layers to the other side of said splicing element.

2. An apparatus for the manufacture of multiple breadths of carpet having layers of vulcanized sponge rubber attached to the undersides thereof, comprising means for conveying two strips of carpet while in edgeto-edge relation, a plow for lifting the layers of sponge rubber from the undersides of the strips, means to apply a splicing tape having an adhesive coated side with said coated side in contact with the exposed undersides of the strips while the sponge rubber layers are separated from the strips, and means to adhesively unite the edges of the sponge rubber layers to the other side of said splicing tape.

3. An apparatus for the manufacture of multiple breadths of carpet having layers of vulcanized sponge rubber attached to the undersides thereof, comprising means for conveying two strips of carpet while in edgeto-edge relation, a plow for lifting the layers of sponge rubber from the undersides of the strips, means to apply a splicing tape having an adhesive coated side with said coated side in contact with the exposed undersides of the strips, means to return the edges of the sponge rubber layers and seal them against the tape, and means to adhesively unite the edges of the'sponge rubber layers to the tape.

4. Apparatus for joining strips of carpet having layers of vulcanized sponge rubber attached to the undersides thereof, comprising a knife for trimming the edges of two carpet strips, a cylindrical conveyor means to receive the two strips after the trimming operation, means to lift the edges of the sponge rubber layers, means operative while said edges are in raised position to apply a splicing strip having an adhesive coated side with said coated side in contact with the exposed edges of the carpet strips, and means to apply adhesive to the other side of said splicing member.

5. Apparatus for joining strips of carpet having layers of vulcanized sponge rubber attached to the undersides thereof, comprising a knife for trimming the edges of two carpet strips, a cylindrical conveyor means to receive the two strips after the trimming operation, a plow to lift the edges of the sponge rubber layers, an applicator behind the plow to attach a splicing strip having an adhesive coated side with said coated side in contact with the junction line of the sponge rubber layers while the sponge rubber layers are separated from the strips, and means to apply adhesive to the other side of said splicing member.

6. Apparatus for joining strips of carpet having layers of vulcanized sponge rubber attached to the undersides thereof, comprising a knife for trimming the edges of two carpet strips, a cylindrical conveyor means to receive the two strips after the trimming operation, a plow to lift the edges of the sponge rubber layers, an applicator behind the plow to attach a splicing strip having an adhesive coated side with said coated side in contact with the junction line of the sponge rubber layers, means to turn the edges of the sponge rubber layers back onto the carpet strips and attach them to the carpet strips, and means to adhesively unite the edges of the sponge rubber layers to the other side of said splicing strip.

7. A method of splicing strips of sponge rubber backed carpeting to provide multiple widths of carpeting comprising .the steps of: applying a foam latex impermeable barrier to the'underside of said strips in a relatively narrow band extending along the selvage edges thereof; applying a layer of foam latex over the entire underside of each strip including said band; curing said layer so that it becomes bonded to said strip except in the area of said band; longitudinally trimming along the selvage edge of each strip and locating the trimmed edges in abutment; separating said cured layers from said strips in the area of said bands; inserting a splicing tape between said separated layers and strips, and'securing said tape to the underside of said strips in the area of said bands. 8. A method of splicing strips of sponge rubber backed carpeting to provide multiple widths of carpeting comprising the steps of: applying a foam latex impermeable barrier to the underside of said strips in a relatively narrow band extending along the selvage edges thereof; applying a layer of foam latex over the entire underside of each strip including said band; curing said layer so that it becomes bonded to said strip except in the area of said band; longitudinally trimming along the selvage edge of each strip and locating the trimmed edges in abutment; separating said cured layers from'said strips in the area of said bands; inserting a splicing tape between said separated layers and strips; turning said separated layers back over said splicing tape; and adhesively securing said tape to said layers and strips in the area of said bands.

9. A method of splicing strips of sponge rubber backedcarpeting to provide multiple widths of carpeting comprising the steps of: applying a foam latex impermeable barrier to the underside of said strips in a relatively narrow band extending along the selvage edges thereof; applying a layer of foam latex over the entire underside of each strip including said band; curing said layer so that it becomes bonded to said strip except in the area of said band; longitudinally trimming along the selvage edge of each strip and locating the trimmed edges in abutment; separating said cured layers from said strips in the area of said bands; inserting a tape having an adhesive coated side between said separated layers and strips, said coated side facing said strips, applying adhesive to the other side of said tape; and. securing said tape to said layers and strips in the area of said bands.

10. A method of splicing strips of sponge rubber backed carpeting to provide multiple Widths of carpeting comprising the steps of: detachably securing a foam latex impermeable barrier to the underside of said strips providing a relatively narrow band extending along the selvage edges thereof; applying a layer of foam latex over the entire underside of each strip including said band; curing said layer so that it becomes bonded to said strip except in the area of said band; longitudinally trimming along the selvage edge of each strip and removing said barrier; locating the trimmed edges in abutment; separating said cured layers from said strips in the area of said bands; inserting a splicing tape between said separated layers and strips; and securing said tape to the underside of said strips inthe area of said bands.

11. A method of splicing strips of sponge rubber backed carpeting to provide multiple widths of carpeting comprising the steps of: detachably securing a foam latex impermeable barrier to the underside of said strips providing a relatively narrow band extending along the selvage edges thereof; applying a layer of foam latex over the entire underside of each strip including said band;

'curinfg said .layer 'so that it becomes bonded to said strip except in :the area of said band; longitudinally triminingialongithe selvage edge of each strip and removing said barrier; locatin the .trimrned edges "in abutment; separating 'said "cured "layersfrom said strips in the area of said "bands; inserting a splicing tape between said separatedlayers and strips; "turning said 'separatedlayers back over said splicing tape; and 'ad'hesively securing said tape to said layers and strips in the area er said bands. 12. A method of'splicingstrips of sponge rubber backed carpeting to provide multiple widths of carpeting comprising the :steps of: detachably securing a foam latex impermeable barrier to "the "underside 'of said strips providing 'a relatively narrow'band extendiirgalbng the 'selvage edges thereof; applying a layer "of foam latex over the entire underside of each strip including said band; curing said layer so that it becomes bonded to said strip except in the area 'of said band; longitudinally trimming along theselva'ge edge-ofeach'strip and rem'oving said barrier; locating the trimmed edges in abutment; separating said cured .layers from said strips in the area of said bands; insertinga tape having an adhesive coated side between said separated layers'and strips, said coated side facing said strips; applying an adhesive to the other side of said tape; and securing said tape to said layers in the area of said bands. 7

13. A method ofsplicing strips of sponge rubber backed carpeting to provide multiple Widths of carpeting cornprising the steps of: detachably securing a foam latex impermeable barrier to the underside of said strips providing a relatively narrow band extending along the 'selvage e'dg'esthereof; applying a layer of foam latex over the entire underside of eachjjstrip including band; cuiirrgfs'aid "layer so that. it beco'infes 'b'on v 0 said strip exceptin the area of said b'and; longitudinally trimming along these'lvage 'edgebf ac h'stripand removing saidb'a'rrierflocating the triinined edges in abutment; separating said cpred layers 'from s'a'id strips in the area of said bands; inserting'a'tapehaving an adhesive coated side between said separated layers and strips, saidcoate'd side facing said strips; applying an 'adhe'siv'etothe other side of said tapef's'ecuiingsaid tape to 'said layers in the areaof -said band; and attaching a'finishing strip along the line at abutmentof saidlayer's.

14. A method of splic'ing'sjtiips of sponge'r'ubbe'rb'acked "carpeting to provide multiple widths 'of carpeting com prising applying to the underside of two carpet strips to be jnin'ed a layer of foam latex, providing a foam latex impermeable barrier along the edge "of each st'i'ip, curing each layer of foam latex so that it becomes bonded to a strip except "in the area of each barrier;

op'eiiin'g the unbonded area along abutting edges of the strips, and securing a splicing tape in said unbonded area t'oboth of said strips.

References Cited in the file of this patent UNITED STATES PATENTS l-, 217,252 Williamson Feb. 27, 1917 1,924,551 Higgins Apr. 29, 1933 2,524,456 Masland Oct. 3, 1950 2,659,687 Moore Nov. 17, '1953 i r M n; 

